Trends in the mining sector

Since 2004, mining and tunneling have been an established and increasingly important part of bauma. The mining sector will present numerous innovations and developments at this year's world-leading trade fair for construction machinery, building material machines, mining machines, construction vehicles and construction equipment which will take place in Munich from April 11–17. The companies already unveiled a number of their trends at the bauma Media Dialog in Munich in January.

The new Certiq machine monitoring system from Atlas Copco Rock Drills AB is now the standard for the company's construction and mining machines. The Certiq system is based on telematics, i.e. wireless data transmission. It allows the owners and operators of above and below-ground drilling equipment for example to monitor the performance of their machines at any time and from any location. With the real-time data available, owners and operators can optimize their machines' equipment to ensure that they achieve maximum productivity and profitability. The Certiq software collects and records a huge amount of data while a machine is operating. These data are then shown on a special web portal in the form of easy-to-understand graphics. Users can easily log on to the portal with their unique login data in order to monitor an individual machine or an entire fleet. The system not only tells users how a machine is currently being used or was used in the past but also gives details of machine availability rates, maintenance requirements and much more. The system even produces performance reports automatically and sends them via e-mail to the owner or operator of the machine.

Bell Equipment has complemented its E series generation of articulated dump trucks with a total of four new models. With the current Bell B25E and B30E dump trucks, the new mid-range B35E and B40E models and the new B45E and B50E large dump trucks, Bell continues to focus on the “classic” categories and still offers the world's largest 6x6 program. The Bell B35E and B40E models are following the general market trend with considerably higher nominal loading capacities. Bell Equipment has made the step towards EU4/Tier4 final with new six cylinder engines from Mercedes-Benz optimized by MTU for off-road operations.

Trackman rubber caterpillar tracks from Continental AG help to ensure safe driving in the construction sector. They resemble closed drive belts with a tread profile on which heavy equipment and traction machines such as transporters or road building machines run. Thanks to the new Armorlug technology, the rubber caterpillar tracks offer even better performance and last longer. A number of layers of material embedded in the drive studs strengthen the material and thus increase its durability. The conveyor belt solutions for the efficient transport of goods are reliable, economical and environmentally friendly too.

Visitors to the trade fair will be able to find out about the latest product solutions in the area of inclined conveying, closed belt systems, heat-resistant conveyor belts, energy-optimized transport or lightweight PVC belts. Cummins Inc., Columbus, Indiana, USA, will present the next generation of ultra-clean engines which meet the EU's Stage V emissions regulations for construction machines and mining/materials handling equipment which are due to come into force in 2019. The engines which produce anything from 55 to 300 kW not only satisfy the “virtually zero emissions” requirement of the Stage V regulations but also offer an increase in power and torque of up to ten percent. The improvements in engine power for Stage V are achieved thanks to an innovative approach when it comes to combustion, airflow and fuel injection systems which allows Cummins to exploit the full potential of the four-cylinder QSF3.8 and QSB4.5 as well as the six-cylinder QSB6.7 and QSL9—with no increase in cubic capacity.

Zetros is a range of HGVs from Daimler AG's Mercedes-Benz brand. They are primarily designed for heavy off-road use. With their conventional bonnet design, they offer very good off-road performance and are low in height. To allow easy maintenance, the engine is accessible without having to tip the driver's cab. The Zetros has a long-bonnet design and is available exclusively with permanent all-wheel drive. Its standard wading depth is 800 mm, while 1,190 mm is optionally possible. The Zetros features an OM 926 LA six-cylinder diesel engine with a cubic capacity of 7.2 l and a power output of 240 kW. Engines with Euro3 and Euro5 emissions values are available. The drivetrain has permanent all-wheel drive as well as a transfer case with an off-road gear ratio of 1:1.69. The Zetros comes as standard with a nine-speed manual gearbox. However, it is also available with a fully automatic gearbox from Allison.

Construction machines, vehicles and equipment as well as mining machines are the principal applications for engines from Deutz AG. The manufacturer will unveil its newly developed TCD 2.2 diesel and gas engine as well as the established TCD 2.9 in a gas version. With up to 55 kW, the TCD 2.2 is a further option for materials handling and compact construction machine applications in particular. Unusually, the engine will be launched in both a diesel and a liquid gas (LPG or fuel gas) version. The gas version will produce 42 kW and is an innovation within Deutz's otherwise diesel-driven product range. The TCD 2.2 will go into production in 2019 to coincide with the EU Stage V emissions norm coming into force. All TCD 2.2 and 2.9 models use the same engine platform. This means numerous synergy effects for customers when it comes to integration, for example with regard to connections or the supply of spare parts.

With the LF-21H, GHH Fahrzeuge GmbH is launching a high-performance LHD with a 21 t loading capacity. The so-called Efficient Drive System (EDS) was optimized specially for mining applications. The environmentally friendly Deutz engine satisfies the highest EU Stage IV emissions norm, as a result of which the need for underground ventilation is minimized. In addition to the standard version, the LHD is available in various cab versions, thus allowing it to be used even in situations with a roadway height of just 2.5 m. A Z linkage designed for ore mining allows the very highest breakout forces and is designed for loading corresponding dump trucks.

The Hazemag Group develops and manufactures machines and other systems for the construction and mining industries. The products and systems are used to prepare and enhance raw materials in the construction industry and to travel underground routes in coal, salt, potash, ore, platinum and diamond mines for example. The Lehigh Cement Company (Heidelberg Cement Group) has ordered a semi-mobile limestone crusher from Hazemag for its Union Bridge site. The system will process up to 2,500 t of limestone per hour—with a feed size of up to 2,000 mm. The material is discharged from a 400 t feed hopper using an HAF 25160 apron feeder. The fines in the feed material are screened at 100 mm using an HRS 2638 roller screen.

Herrenknecht AG supplies tunneling machines with diameters of 0.10 to 19 m for all geologies worldwide. The company also supplies deep drilling rigs and drilling machines for vertical and inclined shafts. One innovation which is to be presented at bauma is a slant directional drilling (SDD) rig. Slant directional drilling is an alternative drilling technique which allows shallow, conventional or unconventional oil and gas deposits to be exploited. It is a symbiosis of horizontal (HDD) and vertical directional drilling (VDD). While the entry angle with HDD is between eight and 18 degrees, it is 90 degrees with respect to the earth's surface with VDD. Deposits at low depths for example can be reached quickly using an angle of 30 degrees, while the angle allows a horizontal deflection for further drilling.

Keestrack N.V. will present the new H4 caterpillar mobile cone crusher (35 to 50 t transport weight). At the heart of the model designed for high-quality secondary or tertiary production with a handling capacity of between 120 and 200 t/h is the proven cone crusher technology which was optimized specifically for mobile use. According to Keestrack, the innovative crusher control and monitoring solutions which have a direct influence over the output capacity and product quality are particularly groundbreaking. As the successor to the Galleon range, the Keestrack H4 has a completely new frame design which allows not only high-performance pre- and post-screening equipment but also the use of innovative drive technologies. As a result, the Keestrack H4 is the world's first mobile cone crusher to offer a highly efficient three-deck post-screening module with an oversize material recycler for the production of three high-grade end products in one pass. Keestrack is offering a choice of two economical drive combinations: direct diesel drive of the crusher with electrical or electro-hydraulic peripherals (conveyors, screen units etc.) or the fully hybrid/“plug-in” version with an electrical crusher drive system powered by an on-board diesel generator or mains electricity.

With the Mobicone MCO 11 PRO mobile cone crusher, Kleemann GmbH, a Wirtgen Group company, is heralding the launch of its newly developed PRO Line. It offers quarry operators particularly robust machines for high-performance applications. The machine is driven by a powerful yet economical diesel-electric drive system which allows operation with an external power supply. The cone crusher with a maximum feed capacity of up to 470 t/h is equipped with the innovative Continuous Feed System (CFS) which ensures efficient use of crushing capacity. The MCO 11 PRO is also ideal for use in linked combinations of machines. In addition, the machine can be transported in one piece and can be quickly put into operational position thanks to hydraulic moving machine components.

Kögel Trailer GmbH & Co. KG will present the new Kögel Multi. This versatile trailer is particularly suitable for transporting building materials and for weather-resistant freight. The platform semi-trailer has a reinforced chassis and a semi-trailer load capacity of 15 t to meet the heavy-duty requirements in the construction industry. Depending on the application, the trailer's aluminum walls can be removed. This makes the Multi ideal for transporting various building materials.

In response to customers' requirements, Komatsu Mining developed the new PC7000. Komatsu designed the 677 t machine with a view to creating the safest and most efficient large hydraulic excavator in its class. The PC7000 is powered by two 1,250 kW diesel engines and is optionally available with an electric drive system. With its 36 m³ shovel or backhoe bucket, the PC7000 is designed for use in a range of conditions. The PC7000 is tailored to the 240 to 290 t 830E and 860E dump trucks from Komatsu. Drivers will notice the machine's improved control system. After all, Komatsu has optimized both the shovel design and the hydraulic system. As a result, the machine can swing around more quickly and the shovel can penetrate the material more easily.

To coincide with bauma, Liebherr-International Deutschland GmbH will launch the Liebherr PR 776, the first infinitely variable hydrostatically powered crawler tractor in the 70-ton category. Designed for the most demanding mining and quarrying applications, it is powered by a Liebherr twelve-cylinder diesel engine with a maximum power of 565 kW. It has a maximum operating weight of 74 t and can be equipped with blades with a capacity of 18 m³ (semi-U blade) or 22 m³ (U blade). Thanks to its modern drive concept, the new PR 776 crawler tractor is extremely economical. The infinitely variable hydrostatic drive system which is used in all Liebherr crawler tractors is an innovation in this class of machines. Another advantage of the modern drive concept is the needs-based feed pressure supply. If, for example, the full feed pressure supply is not required during operation, this is automatically returned.

For mining and gravel extraction operations, MAN Truck & Bus AG is offering the tough and resilient MAN TGS chassis from its WorldWide product family in markets outside Europe. The vehicles are optimized to meet sector requirements: The tandem axle unit on the MAN TGS 33.480 6x6 BB now has a longer wheelbase of 1500 millimeters. This means that large-format 16 R 20 tires can be fitted. If the ground conditions require them, 24 R 20.5 format tires also fit on the tippers. The MAN TGS dumper truck, designed for a gross permitted weight of 33 tonnes, is therefore ideal as an alternative to the articulated dumper which is significantly more expensive to purchase. The MAN TGS WorldWide, designed by the Munich-based commercial vehicle manufacturer, is a truck to cope with challenging road situations as well as extreme climatic conditions such as icy temperatures, snow and extreme heat. The heat retention function, which remains active in neutral, has proven itself in Arctic climatic regions and in frosty winters. It ensures operational capability of the vehicle in temperatures of up to minus 40 °C.

With the new P450 tippers in the Heavy Duty segment, F. X. Meiller Fahrzeug- und Maschinenfabrik GmbH & Co KG has reanimated the “tipper versus dumper” discussion. The new rear tipper superstructure improves performance of the heavy-duty tipper trucks even further, and the new subframe and more roomy tipper body shape lowers the center of gravity of the vehicle, enhancing stability in a targeted manner. With a real volume of 28 cubic meters, these tippers offer the same circulating capacities as dumper concepts and, depending on the routes involved, the trucks really demonstrate their advantages, as their turnaround speed is higher. They can use roads when empty or partially loaded, and a change of location can be realized without any heavy or special transport measures. The i.s.a.r. remote control comes into play for securing tipper loads. It replaces the traditional valve control next to the driver's seat and also integrates all auxiliary functions of the tipper operation in one control element. The electric shifting tarpaulin can be opened and closed safely, comfortably and without losing time. The (optional) servo controls, which reduce the number of steps required and practically eliminate the potential for operation errors, are a new feature.

MTG, of Premià de Mar, north of Barcelona, has expanded its range of teeth for rope shovels with the new RSS and RSXX tooth designs. These two new designs complete the MTG Systems Starmet range of teeth for rope shovels. The RSS tooth is ideal in tough, high-impact applications, and it is particularly suitable for cases in which the tooth may be subjected to leverage overexertion. The RSXX is specially reinforced with plenty of wear material, making it a highly resistant tooth, perfect for very tough applications with an extreme level of abrasion and very high impact. The two new designs join the existing ones (RS, RSX and EX) and, alongside the MTG Systems StarMet Rope Shovels range of adapters and shrouds, they offer a complete solution for protecting electric rope shovel buckets and they enable the most common lip configurations to be equipped.

SBM Mineral Processing GmbH supplies equipment for many stages along the processing chain: for crushing, classifying, conveying, stockpiling, washing and dewatering. The jaw crusher STE 100.60 was newly developed for crushing limestone, granite, building rubble and also slag. The new overload protection function (Gap Release Control) prevents “unbreakable parts” from damaging or blocking the crusher. And the automatic gap adjustment opens the crusher gap so that an unbreakable (metal) part can safely leave the crusher. Afterwards the movable crushing jaw resumes the predefined normal position and the crushing process continues without any further delay.

As well as trucks and engines Scania CV AB will also be showcasing its mining division at bauma. Transport accounts for more than a third of operational mining costs, and this manufacturer is aiming to bring about a positive change in its customers’ bottom line. The mining business faces new and tough challenges with an even stronger focus on cost-efficient solutions and operational excellence. Scania’s focus is on helping mining customers to improve productivity, lower costs, and better manage risks, leading to improved business results.

Schäffer Maschinenfabrik GmbH is expanding its construction machinery range by four high-performance wheel loaders with “Z-Kinematics”, with engine outputs varying between 37 kW and 75 kW. One of them is the new 5650 Z, which features a bucket capacity of 0.8 cubic meters and a working weight of 4.5 tonnes and was constructed to meet the high performance requirements. The new wheel loader is equipped with a powerful Kubota engine with 37 kW, a displacement of 2.6 l, and four-valve technology. This machine is the first to feature electric drive control which permits significant increases in efficiency. The electronic support helps to optimally use the engine output and transform it into thrust, which results in reduced fuel consumption. The electronic control furthermore enables several new safety functions, such as overheat protection, which make working with the 5650 Z even more safe and reliable. The maximum lifting height of the new wheel loader is 3.40 m. At up to 2.5 tonnes, the tipping load is likewise very high. The applications of the 5650 Z can be expanded significantly by an optional registration as a tractor unit with towing capacity of up to 6 tonnes and the optional overdrive up to 30 km/h.

Technology from Schauenburg Maschinen- und Anlagen-Bau GmbH is in use everywhere where new tunnels are being built, connections created, raw materials extracted and new energy sources opened up. The company´s product spectrum encompasses machinery and equipment for tunneling and special civil engineering applications, and mining. The focus is on systems for slurry treatment. Efficient separation plants are the cornerstone of the successful application of fluid-based soil removal systems for tunneling, microtunneling, HDD and diaphragm wall construction. For the field of mining Schauenburg develops hydromechanical wet-processing systems as a first stage in extracting ores. The ore-containing rock is washed, classified and sorted according to specific weight. This significantly reduces operating costs in the downstream processes.

Siemens AG is offering mining companies a gearless drive system for SAG mills with a tube diameter of 42 feet. This enables throughput to be almost doubled in comparison with the 38-foot mills commonly used today. With this innovation, Siemens is responding to the rising demand for larger and more powerful drives in mining. The principal component of the new drive system is a ring motor with a width of 25 meters and a height of 20 meters. The 42-foot ring motor is the centerpiece of the gearless drive and wrapped around the tube mill. An increase in tube diameter means that the mass of the ore being ground rises dramatically, and hence also the strain on structural elements and the motor. During the design of the motor, therefore, all components were subjected to comprehensive and detailed risk analysis.

Open-pit hard rock mines extracting iron ore and other materials use monster trucks. The investment costs, fuel consumption and associated CO2 emissions are immense. With its Integrated Skip Conveying And Crushing System, ThyssenKrupp Resource Technologies offers a sustainable and cost-effective alternative. Unlike in truck haulage, where not only the payload but also the deadweight of the truck has to be moved, the Integrated Skip Conveying And Crushing System only uses energy to transport the payload. The reason for this lies in the special design of the system, which ensures that the deadweights of the skips balance each other out. Two skips are connected by a common rope sheave drive system and can convey a complete truck load on rails from the loading station to the crusher at the top of the mine, using the shortest possible route over gradients of up to 75 degrees. Further transportation of the material from the crusher can then be carried out efficiently by belt conveyors.

The new 55-tonne capacity A60H from Volvo Construction Equipment (Volvo CE) meets growing customer demand for articulated haulers with larger capacities. More than half of the articulated haulers sold globally by all manufacturers today are within the Volvo A40 size class. The Volvo A60H’s higher payload—a 40% increase on Volvo’s A40 models—significantly lowers the cost-per-tonne ratio for hauler customers. The new size also offers a viable alternative to rigid dump trucks and construction trucks operating on soft, uneven or steep roads, allowing a similar amount of material to be hauled in a shorter cycle time. Using articulated haulers also reduces the level of maintenance required for haul roads on the jobsite, further improving profitability. Good stability, comfort and high hauling speeds are ensured by the matched drivetrain, automatic drive combinations (including 100% differential locks), all-terrain bogie, hydro-mechanical steering and active suspension.

In December 2013 the Zeppelin Group took over sales and servicing of the mining machinery of Caterpillar Global Mining. Coal is extracted underground in a process of longwall mining. The longwall mining equipment includes safety shields, the extraction machine and the chain scraper conveyor for transporting away the released coal. In cutting extraction the shearer loader with two cutting rollers is used. With low seam heights the coal is pared off using a drag hook plow or a Gleithobel plow. The armored face conveyor serves as the guide for the extraction machines. To keep the conveying space open and the workplace safe for the miners, safety shields are used. At bauma Zeppelin will be presenting the GH 800 plow system. This is being presented together with three safety shields from RAG Anthrazit Ibbenbüren. The Cat tunneling excavator 328DLCR from Zeppelin Baumaschinen GmbH has a specially designed boom and a tail swing radius of just 1.90 m. The boom is optimized for European tunnel profiles and for low working heights, enabling the excavator to achieve an advance of 2.30 m at a working height of 5.50 m. That means it is the only 43-tonne tunneling excavator which operates in the space taken up by a 27-tonne machine, but it can advance much faster, thanks to its higher power. Because it takes up less space, this means the tunnel profile can be reduced, thus reducing material volumes and making tunnel construction easier.